Phase cable upgrade with magnet wire

[John in CR]

Good job e-beach. Have several extra inches and stagger the ends going in first with the halls even shorter. It's all about getting enough of the end thru to grab good and help from both ends to get it past the bend. With only 3 you can scrape the varnish off after getting them thru. Do the halls before putting them into the bundle.

Good to see someone using my ideas. I generate so many a day that i only get to use a few of them myself, and the vast majority are pretty good ones.

John

 

[ian.mich]

how do you plan to get it around the bend? 10awg solid core does not bend easy at all. once you have it bent around the hole and sticking out its fairly easy after that

 

[e-beach]

how do you plan to get it around the bend? 10awg solid core does not bend easy at all. \

The way the bundle will be wrapped it will have the wires staggered. One long strand of 10 to start the bend along with a small screw driver. I have practiced a bit and it is fairly simple to get a small screwdriver blade under one strand of the wire and give a wiggle up-word. A little push into the axle, a wiggle on the first strand, repeat the movement until it is out of the whole. As it progresses the second and then the third strand will come through and then eventually all of them. From my test run it shouldn't take but 10 - 20 minutes. That is the plan anyway.

 

[ian.mich]

how do you plan to get it around the bend? 10awg solid core does not bend easy at all. \

The way the bundle will be wrapped it will have the wires staggered. One long strand of 10 to start the bend along with a small screw driver. I have practiced a bit and it is fairly simple to get a small screwdriver blade under one strand of the wire and give a wiggle up-word. A little push into the axle, a wiggle on the first strand, repeat the movement until it is out of the whole. As it progresses the second and then the third strand will come through and then eventually all of them. From my test run it shouldn't take but 10 - 20 minutes. That is the plan anyway.

manage to do it?

 

[e-beach]

manage to do it?

Not yet...

I got to the point where I was beginning to wiggle the mag wire out of the hole at the base of the inside of the axle and the shrink tubing started to bind at the entry point at the outside end of the axle. I only used 5 inches of shrink tubing because I didn't want to run the shrink tube the length of the the insertion only to have to cut it off once in came out of the axle on the inside. I was going to add more later inside the axle to color code the wires. I just didn't want to have to run it the whole length of the wiring only to cut it off ...but it looks like that is what I will have to do anyway.

I wasn't using any lub to help slip the harness through the bore hole, but it probably needs that as well. I am thinking plumbers silicone grease.

But before I could go any farther then the picture below, my mother nominated me to build her some sliding draws inside her existing kitchen cabinets. Apparently she didn't like the bid that she got from her local cabinet store. And, she knows that I can give her the best price in town.

So, my 10 AWG magnet wiring harness is in hiatus at the moment until I finish the cabinetry.

 

[Rodney64]

I was looking at replacing my phase wires on my H4080 I ave shrink wrapped them. The wires has previously melted together.

The melted phase wires were difficult to go though the axle without scraping and damaging some of the shrink wrap. If I removed all the melted plastic from the phase wires and shrink wrap individually then tapping would this be ok.
I have shrink wrap but not sure if its rated to 160 degrees or not.

 

[ian.mich]

I was looking at replacing my phase wires on my H4080 I ave shrink wrapped them. The wires has previously melted together.

The melted phase wires were difficult to go though the axle without scraping and damaging some of the shrink wrap. If I removed all the melted plastic from the phase wires and shrink wrap individually then tapping would this be ok.
I have shrink wrap but not sure if its rated to 160 degrees or not.

Shrink the hall wires that are already in there, buy a spool of 200c 16awg mag wires, cut 9 pieces of 16awg that are long enuff to reach from outside to the windings with wire to spare, shrink 3pieces individually so you have 3x3 wires, feed those 3 inside the motor and put lots of shrink and the two ends of the tube (i assume this is the hollow-axle type). Add e-tape and shrink around all 3 phases if possible.